Semiconductor module, upper and lower arm kit, and three-level inverter

ABSTRACT

A semiconductor module, an upper and lower arm kit, and a three-level inverter can be provided with low cost and broad current ratings and voltage ratings using existing packages, without developing new packages. 
     A first semiconductor module ( 100 ) on an upper arm side and a second semiconductor module ( 200 ) on a lower arm side are formed using an existing package, and the semiconductor modules ( 100 ) and ( 200 ) are used to configure an upper and lower arm kit ( 300 ). Further, the upper and lower arm kit ( 300 ) is used to configure a three-level inverter ( 500 ). These devices can be formed using existing packages ( 56 ), and semiconductor modules ( 100 ), ( 200 ), an upper and lower arm kit ( 300 ), and a three-level inverter ( 500 ) can be therefore provided with low cost and broad current ratings and voltage ratings.

TECHNICAL FIELD

This invention relates to a semiconductor module, an upper and lower armkit formed of the semiconductor module, and a three-level inverterformed of the upper and lower arm kit.

BACKGROUND ART

FIG. 13 is a circuit diagram of a three-level inverter of the prior art,which converts direct current into alternating current.

In FIG. 13, the drawing symbols 51 and 52 denote DC power suppliesconnected in series, the positive and negative electrode potentials aredenoted by P and N respectively, and the neutral point potential isdenoted by M. When the DC power supplies 51 and 52 are configured froman AC power supply system, the configuration can use diode rectifiers,large-capacitance electrolytic capacitors and similar which are notshown.

Between the positive electrode potential P and the negative electrodepotential N are connected series-connected circuits, of insulated-gatebipolar transistors (hereafter “IGBTs”) with antiparallel-connecteddiodes, for three phases. That is, a series-connected circuit 60 for a Uphase is a series-connected circuit of an upper arm formed of an IGBT(T1) with an antiparallel-connected diode D1, and a lower arm formed ofa IGBT (T2) with an antiparallel-connected diode D2; a series-connectedcircuit 61 for a V phase is a series-connected circuit of an upper armformed of an IGBT (T3) with an antiparallel-connected diode D3, and alower arm formed of a IGBT (T4) with an antiparallel-connected diode D4;and a series-connected circuit 62 for a W phase is a series-connectedcircuit of an upper arm formed of an IGBT (T5) with anantiparallel-connected diode D5, and a lower arm formed of a IGBT (T6)with an antiparallel-connected diode D6.

Between the series connection point of the upper arm and lower arm andthe DC neutral point potential M of the series-connected circuit foreach phase is connected an AC switch in which is an antiseries-connectedIGBT with an antiparallel-connected diode. That is, an AC switch,configured with the emitter of an IGBT module 63 formed of an IGBT 81with an antiparallel-connected diode 82 connected to the emitter of anIGBT module 64 formed of an IGBT 83 with an antiparallel-connected diode84, is connected between the series connection point and the DC powersupply neutral point M of the series-connected circuit 60 for the Uphase; an AC switch, configured with the emitter of an IGBT module 65formed of an IGBT 85 with an antiparallel-connected diode 86 connectedto the emitter of an IGBT module 66 formed of an IGBT 87 with anantiparallel-connected diode 88, is connected between the seriesconnection point and the DC power supply neutral point M of theseries-connected circuit 61 for the V phase; and, an AC switch,configured with the emitter of an IGBT module 67 formed of an IGBT 89with an antiparallel-connected diode 90 connected to the emitter of anIGBT module 68 formed of an IGBT 91 with an antiparallel-connected diode92, is connected between the series connection point and the DC powersupply neutral point M of the series-connected circuit 62 for the Wphase. The output of the series connection point of each of theseries-connected circuits 60, 61, 62 is an AC output, and is connectedto the load 74 via respective filtering inductors 71, 72, 73.

By using this circuit configuration, the series connection points ofeach of the series-connected circuits 60, 61, 62 can output the positiveelectrode potential P, negative electrode potential N, and neutral pointpotential M, for three-level inverter output. FIG. 14 shows an exampleof an output voltage (Vout) waveform. A feature compared with atwo-level type inverter is the output of an AC voltage having threevoltage levels with few lower-order harmonic components, so that thefiltering inductors (output filters) 71 to 73 can be miniaturized.

Next, the three-level inverter of the prior art described in PatentDocument 1 is explained using FIG. 15.

FIG. 15 is a diagram of the configuration of upper and lower arms forone phase, including an AC switch, of a three-level inverter; here FIG.15( a) is a circuit diagram, and FIG. 15( b) is a perspective view ofthe semiconductor module.

The semiconductor module 40 shown in FIG. 15( b) accommodates an ACswitch 53, in which two reverse blocking IGBTs 54 and 55 areantiparallel-connected, as shown in FIG. 15( a), and two IGBTs (T1 andT2).

FIG. 16 is a schematic cross-sectional view of the semiconductor module.In the semiconductor module 40, power semiconductor chips 43 (denoted bythe symbols T1, T2, D1, D2, 54 and 55 in FIG. 15) are mounted on aninsulating substrate 42 on a heat-dissipating metal base 41, metalterminals 44 leading to outside are exposed on the upper face of thepackage 45, and the interior of the package 45 is packed with resin 46.

This semiconductor module 40 is applied to a voltage-type three-levelinverter. The semiconductor module 40 is formed of the first IGBT (T1)having a collector terminal C1 connected to the positive electrodeterminal (P terminal) of the series-connected circuit 60 and having thediode D1 antiparallel-connected thereto, and the second IGBT (T2) havinga collector connected to the emitter of the first IGBT (T1), an emitterterminal E2 connected to the negative electrode terminal (N terminal) ofthe series-connected circuit 60, and the diode D2 antiparallel-connectedthereto.

The semiconductor module 40 is also formed of the AC switch 53,configured using the first reverse blocking IGBT 54 the collector ofwhich is connected to the emitter of the first IGBT (T1) and the secondreverse blocking IGBT 55 antiparallel-connected to the first reverseblocking IGBT 54.

The series-connected circuit 60 is configured using the first IGBT (T1)with the antiparallel-connected diode D1 and the second IGBT (T2), thepositive electrode terminal (P terminal) of the series-connected circuit60 is connected to the collector terminal C1 of the first IGBT, and thenegative electrode terminal (N terminal) is connected to the emitterterminal E2 of the second IGBT (T2).

The AC switch 53 is configured using the first reverse blocking IGBT 54and the second reverse blocking IGBT 55.

Further, the AC switch 53 is connected between the connection point E1C2of the emitter of the first IGBT (T1) and the collector of the secondIGBT (T2), and the intermediate potential terminal (M terminal) at anintermediate potential between the positive electrode terminal (Pterminal) and negative electrode terminal (N terminal) of theseries-connected circuit 60. The first IGBT (T1), second IGBT (T2),first reverse blocking IGBT 54 and second reverse blocking IGBT 55 areaccommodated in a single package 45.

In this way, one upper and lower arm is accommodated in one package 45,and when three of these packages 45 are used to configure a three-levelinverter, external wiring is simplified. Further, the wiring inductanceof the three-level inverter can be reduced, and the device as a wholecan be miniaturized.

Here, a reverse blocking IGBT is an IGBT having a reverse-directionbreakdown voltage (reverse breakdown voltage) equal to theforward-direction breakdown voltage (forward breakdown voltage), andbecause the forward breakdown voltage and reverse breakdown voltage areequal, the device is sometimes called a symmetrical IGBT.

Further, an IGBT not having a reverse breakdown voltage refers to whatis called an asymmetrical IGBT the reverse breakdown voltage of which ismuch lower than the forward breakdown voltage, and in for example aninverter circuit in which a reverse breakdown voltage is not applied, isfrequently used with an antiparallel-connected freewheeling diode.Normally, “IGBT” simply means an IGBT without a reverse breakdownvoltage.

Further, Patent Documents 2 to 4 disclose so-called single units of asemiconductor module, in which two types of modules are prepared withthe lead positions of the emitter terminals and collector terminalsswapped, the two module types disposed in a row, and by connecting theemitter terminal of one module to the collector terminal of the otheradjacent module, one upper and lower arm of an inverter are configured.

Patent Document 1: Japanese Patent Application Laid-open No. 2008-193779

Patent Document 2: Japanese Patent Application Laid-open No. H3-108749

Patent Document 3: Japanese Patent Application Laid-open No. H3-65065

Patent Document 4: Japanese Patent Application Laid-open No. H9-9644

However, when manufacturing a three-level inverter using thesemiconductor module shown in FIG. 15, depending on the capacity of thethree-level inverter, the IGBTs, reverse blocking IGBTs and othersemiconductor elements incorporated within the module are changed. Thatis, in order to increase the capacity, the semiconductor element chipsize may be changed, or parallel connections of IGBTs and reverseblocking IGBTs may be made. Thus when preparing three-level inverterswith various capacities, dedicated semiconductor module packages 45 mustbe newly developed according to the IGBTs, reverse blocking IGBTs, andother semiconductor elements incorporated. Consequently in order tosupport a broad range of currents from tens of amperes to thousands ofamperes, a number of packages must be newly prepared. Moreover, in orderto support a broad range of breakdown voltages from hundreds of volts toover a thousand volts, a number of packages must be newly prepared.

There are also cases in which the first and second IGBTs (T1 and T2) andthe first and second reverse blocking IGBTs 54 and 55 are used inseparate packages 56 a and 57 (see FIG. 17 and FIG. 19) to configure athree-level inverter.

FIG. 17 shows the configuration of inverter upper and lower arms for onephase; FIG. 17( a) is a circuit diagram, and FIG. 17( b) is a plane viewof principal components of the semiconductor module. In the exampleshown, the three main terminals (E1C2, E2 and C1) are disposed in onerow on the upper face of the package 56 a.

FIG. 18 is a diagram of the inner structure of the semiconductor moduleof FIG. 17. The E1C2 terminals at a and b are connected within thepackage 56 a, and what is disposed above the package 56 a is E1C2 a.

FIG. 19 shows the configuration of an AC switch in which reverseblocking IGBTs are antiparallel-connected. FIG. 19( a) is a circuitdiagram, and FIG. 19( b) is a plane view of the AC switch package.

The three-level inverter shown in FIG. 15 is configured combiningsemiconductor modules 47 of first and second IGBTs (T1 and T2) upper andlower arms (series-connected circuit 60) shown in FIG. 17 and FIG. 18,and AC switches 53 shown in FIG. 19 using first and second reverseblocking IGBTs 54 and 55. In this case, the package of a semiconductormodule 47 shown in FIG. 17 is an existing package 56 a, and is anormally used two-unit package accommodating an upper arm element and alower arm element. On this existing package 56 a are disposed the threemain terminals (E1C2, C1 and E2).

However, the package 57 of the AC switch 53 shown in FIG. 19( b) differsfrom the internal wiring circuit configuration of the semiconductormodule 47 shown in FIG. 17 and FIG. 18 in that there are two mainterminals (the K terminal and L terminal), and so the package 56 a ofFIG. 17( b) cannot be used.

For this reason, a package 57 accommodating the first and second reverseblocking IGBTs 54 and 55 must be newly developed according to thecurrent rating and voltage rating.

When manufacturing a three-level inverter, a new package must bedeveloped both in cases where the semiconductor module 40 of FIG. 15(new package 45) is used, and in cases where the semiconductor module 47of FIG. 17 (existing package 56 a) and the AC switch 53 of FIG. 19 (newpackage 57) are combined and used.

Further, Patent Documents 2 to 4 do not indicate that by changingsemiconductor elements disposed in the interior using existing packageswith external terminals in the same positions, two types of modules withthe same package shape are formed, and the two types of modules are usedto configure one upper and lower arm of a three-level inverter.

DISCLOSURE OF THE INVENTION

An object of this invention is to resolve the above problems to providea semiconductor module, an upper and lower arm kit and a three-levelinverter with low cost and broad current ratings and voltage ratingsusing existing packages, without developing new packages.

In order to attain the above object, a semiconductor module is providedas follows. A semiconductor module has a first switching element nothaving a reverse breakdown voltage, and antiparallel-connected to afreewheeling diode; a first reverse blocking switching element having areverse breakdown voltage, and series-connected to the first switchingelement; a first package, in which the first switching element and thefirst reverse blocking switching element are accommodated; ahigh-potential side terminal (C11), disposed on an upper face of thefirst package and connected to the high-potential side of the firstswitching element; a first intermediate potential auxiliary terminal(M11), disposed on the upper face of the first package and connected tothe low-potential side of the first reverse blocking switching element;and a first connection terminal (Q11), disposed on the upper face of thefirst package and connected to the first switching element and to thefirst reverse blocking switching element.

Further, the semiconductor module is provided as follows. The firstswitching element is an insulated-gate bipolar transistor not having areverse breakdown voltage, and the first reverse blocking switchingelement is a reverse blocking insulated-gate bipolar transistor having areverse breakdown voltage, the collector of which is the high-potentialside and the emitter of which is the low-potential side.

Further, in order to attain the above object, a semiconductor module isprovided as follows. The semiconductor module has a second reverseblocking switching element having a reverse breakdown voltage; a secondswitching element not having a reverse breakdown voltage,series-connected to the second reverse blocking switching element andantiparallel-connected to a freewheeling diode; a second package, inwhich the second reverse blocking switching element and the secondswitching element are accommodated; a second intermediate potentialauxiliary terminal (M22), disposed on an upper face of the secondpackage and connected to the high-potential side of the second reverseblocking switching element; a low-potential side terminal (E22),disposed on the upper face of the second package and connected to thelow-potential side of the second switching element; and a secondconnection terminal (Q22), disposed on the upper face of the secondpackage, and connected to the second reverse blocking switching elementand to the second switching element.

Further, the semiconductor module is provided as follows. The secondswitching element is an insulated-gate bipolar transistor not having areverse breakdown voltage, and the second reverse blocking switchingelement is a reverse blocking insulated-gate bipolar transistor having areverse breakdown voltage, the collector of which is the high-potentialside, and the emitter of which is the low-potential side.

Further, in order to attain the above object, an upper and lower arm kitis provided as follows. The upper and lower arm kit is formed of a pairof a first semiconductor module to be an upper arm and a secondsemiconductor module to be a lower arm in a three-level inverter. Thefirst semiconductor module has a first switching element not having areverse breakdown voltage, and antiparallel-connected to a freewheelingdiode; a first reverse blocking switching element having a reversebreakdown voltage, and series-connected to the first switching element;a first package, in which the first switching element and the firstreverse blocking switching element are accommodated; a high-potentialside terminal (C11), disposed on an upper face of the first package andconnected to the high-potential side of the first switching element; afirst intermediate potential auxiliary terminal (M11), disposed on theupper face of the first package and connected to the low-potential sideof the first reverse blocking switching element; and a first connectionterminal (Q11), disposed on the upper face of the first package andconnected to the first switching element and to the first reverseblocking switching element. The second semiconductor module has a secondreverse blocking switching element having a reverse breakdown voltage; asecond switching element not having a reverse breakdown voltage,series-connected to the second reverse blocking switching element andantiparallel-connected to a freewheeling diode; a second package, inwhich the second reverse blocking switching element and the secondswitching element are accommodated; a second intermediate potentialauxiliary terminal (M22), disposed on an upper face of the secondpackage and connected to the high-potential side of the second reverseblocking switching element; a low-potential side terminal (E22),disposed on the upper face of the second package and connected to thelow-potential side of the second switching element; and a secondconnection terminal (Q22), disposed on the upper face of the secondpackage, and connected to the second reverse blocking switching elementand to the second switching element.

Further, a three-level inverter in which three of the upper and lowerarm kits are disposed in parallel is provided. In the three-levelinverter, the high-potential side terminals (C11 terminals) of the firstsemiconductor modules are connected together by a third connectionconductor; the low-potential side terminals (E22 terminals) of thesecond semiconductor modules are connected together by a fourthconnection conductor; the intermediate potential auxiliary terminal(M11) of each of the first semiconductor modules and the intermediatepotential auxiliary terminal (M22) of each of the second semiconductormodules are connected together by a fifth connection conductor; thethird connection conductor and the fifth connection conductor arerespectively connected to a positive electrode and a negative electrodeof a first DC power supply; the fifth connection conductor and thefourth connection conductor are respectively connected to a positiveelectrode and a negative electrode of a second DC power supply; thefirst connection terminal (Q11) of each of the first semiconductormodules and the second connection terminal (Q22) of each of the secondsemiconductor modules are connected together by a sixth connectionconductor; and the three sixth connection conductors are taken to beoutput terminals which are the U terminal, the V terminal, and the Wterminal.

Further, in order to attain the above object, an upper and lower arm kitis provided as follows. The upper and lower arm kit includes a firstsemiconductor module and a second semiconductor module. The firstsemiconductor module has a first switching element not having a reversebreakdown voltage, and antiparallel-connected to a freewheeling diode; afirst reverse blocking switching element having a reverse breakdownvoltage, and series-connected to the first switching element; a firstpackage, in which the first switching element and the first reverseblocking switching element are accommodated; a high-potential sideterminal (C11), disposed on an upper face of the first package andconnected to the high-potential side of the first switching element; afirst intermediate potential auxiliary terminal (M11), disposed on theupper face of the first package and connected to the low-potential sideof the first reverse blocking switching element; and a first connectionterminal (Q11), disposed on the upper face of the first package andconnected to the first switching element and to the first reverseblocking switching element. The second semiconductor module has a secondreverse blocking switching element having a reverse breakdown voltage; asecond switching element not having a reverse breakdown voltage,series-connected to the second reverse blocking switching element andantiparallel-connected to a freewheeling diode; a second package, inwhich the second reverse blocking switching element and the secondswitching element are accommodated; a second intermediate potentialauxiliary terminal (M22), disposed on an upper face of the secondpackage and connected to the high-potential side of the second reverseblocking switching element; a low-potential side terminal (E22),disposed on the upper face of the second package and connected to thelow-potential side of the second switching element; and a secondconnection terminal (Q22), disposed on the upper face of the secondpackage, and connected to the second reverse blocking switching elementand to the second switching element. The first connection terminal (Q11terminal) and second connection terminal (Q22 terminal) are connected bya first connection conductor, and the intermediate potential auxiliaryterminal (M11 terminal) of the first semiconductor module and theintermediate potential auxiliary terminal (M22 terminal) of the secondsemiconductor module are connected by a second connection conductor.

Further, a three-level inverter in which three of the upper and lowerarm kits are disposed in parallel is provided. In the three-levelinverter, the output terminals of the three-level inverter which are theU terminal, the V terminal, and the W terminal, are connected to thethree first connection conductors, respectively; the second connectionconductors are connected together as an intermediate potential terminal(M terminal); the high-potential side terminals of the firstsemiconductor modules are connected together and to the positiveelectrode of a first DC power supply via a third connection conductor (Pterminal); the negative electrode of the first DC power supply isconnected to the intermediate potential terminal (M terminal); thelow-potential side terminals of the second semiconductor modules areconnected together and to the negative electrode of a second DC powersupply via a fourth connection conductor (N terminal); and the positiveelectrode of the second DC power supply is connected to the intermediatepotential terminal (M terminal).

By means of this invention, existing packages (with three mainterminals) can be used to configure a semiconductor module, an upper andlower arm kit, and a three-level inverter, so that design efficiency canbe improved and package members can be used in common without the needto develop new packages, and consequently costs can be lowered.

Further, various existing packages can be used to configure circuits, sothat semiconductor modules, upper and lower arm kits, and three-levelinverts with broad ranges of current ratings and voltage ratings can beprovided.

The above and other objects, features and advantages of the inventionwill become clear through the following explanations in relation to theattached drawings which show preferred embodiments as examples of theinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram of the configuration of the semiconductor module ofa first example of the invention, in which FIG. 1( a) is a circuitdiagram of principal components and FIG. 1( b) is a plane view ofprincipal components;

FIG. 2 is a diagram of the internal configuration of the semiconductormodule of FIG. 1;

FIG. 3 is a diagram of the configuration of the semiconductor module ofa second example of the invention, in which FIG. 3( a) is a circuitdiagram of principal components and FIG. 3( b) is a plane view ofprincipal components;

FIG. 4 is a diagram of the internal configuration of the semiconductormodule of FIG. 3;

FIG. 5 is a circuit diagram of principal components of the upper andlower arm kit of a third example of the invention;

FIG. 6 is a plane view of principal components of the upper and lowerarm kit of the third example of the invention;

FIG. 7 is a circuit diagram of principal components of the upper andlower arm kit of a fourth example of the invention;

FIG. 8 is a plane view of principal components of the upper and lowerarm kit of the fourth example of the invention;

FIG. 9 is a circuit diagram of principal components of the three-levelinverter of a fifth example of the invention;

FIG. 10 is a plane view of principal components in a configurationdiagram of the three-level inverter of the fifth example of theinvention;

FIG. 11 is a circuit diagram of principal components of the three-levelinverter of a sixth example of the invention;

FIG. 12 is a plane view of principal components in a configurationdiagram of the three-level inverter of the sixth example of theinvention;

FIG. 13 is a circuit diagram of a three-level inverter of the prior artwhich converts a direct current into an alternating current;

FIG. 14 is a diagram of an output voltage (Vout) waveform example of athree-level inverter;

FIG. 15 is a diagram of the configuration of an upper and lower arm forone phase, including an AC switch of a three-level inverter, in whichFIG. 15( a) is a circuit diagram and FIG. 15( b) is a perspective viewof the semiconductor module;

FIG. 16 is a schematic cross-sectional view of a semiconductor module;

FIG. 17 shows the configuration of inverter upper and lower arms for onephase, in which FIG. 17( a) is a circuit diagram, and FIG. 17( b) is aplane view of principal components of the semiconductor module;

FIG. 18 is a diagram of the inner structure of the semiconductor moduleof FIG. 17; and

FIG. 19 shows the configuration of an AC switch in which reverseblocking IGBTs are antiparallel-connected, in which FIG. 19( a) is acircuit diagram, and FIG. 19( b) is a plane view of the AC switchpackage.

BEST MODE FOR CARRYING OUT THE INVENTION

Embodiments are explained using the following examples.

Example 1

FIG. 1 is a diagram of the configuration of the semiconductor module ofa first example of the invention, in which FIG. 1( a) is a circuitdiagram of principal components and FIG. 1( b) is a plane view ofprincipal components. FIG. 2 is a diagram of the internal configurationof the semiconductor module of FIG. 1. In FIG. 2 and example is shown inwhich four first reverse blocking IGBTs 5, having a reverse breakdownvoltage, are parallel-connected, four first IGBTs 1 (normally usedIGBTs), not having a reverse breakdown voltage, are connected inparallel, and four FWDs (freewheeling diodes) 2 areantiparallel-connected to each of the first IGBTs 1. This is the same asthe case in which the FWDs (D2) in FIG. 18 are eliminated. The Q11terminals a and b are connected within the package 56, and the Q11terminal a is disposed on the package 56, corresponding to the terminalE1C2 in FIG. 17.

A feature of this first semiconductor module 100 is that the first IGBT1 not having a reverse breakdown voltage and antiparallel-connected tothe FWD 2 of the upper arm of a series-connected circuit of thethree-level inverter, and the first reverse blocking IGBT 5 having areverse breakdown voltage of the AC switch, are accommodated in the samepackage 56 as an existing package 56 a.

In the configuration of FIG. 1, the first semiconductor module 100 isconfigured with the first IGBT 1, with an antiparallel-connected FWD 2,series-connected to the first reverse blocking IGBT 5, and the emitterof the first IGBT 1 and collector of the first reverse blocking IGBT 5connected by the connection point 9 a.

On the package 56 are disposed the high-potential side terminal 7 (C11),connected to the collector of the first IGBT 1, the first intermediatepotential auxiliary terminal 11 (M11), connected to the emitter of thefirst reverse blocking IGBT 5, and the first connection terminal 9(Q11), connected to the connection point 9 a of the emitter of the firstIGBT 1 and the collector of the first reverse blocking IGBT 5.

Further, on the package 56 are disposed the gate terminals G1 and G2 andauxiliary emitter terminals E1 and E2 of the first IGBT 1 and the firstreverse blocking IGBT 5 respectively. Q11 described above is a terminalcorresponding to E1C2 in FIG. 17.

The first IGBT 1 with the FWD 2 antiparallel-connected is an element inan upper arm of a three-level inverter 500 (see FIG. 9 and FIG. 10), andthe first reverse blocking IGBT 5 is an element in a portion of an ACswitch 15 (see FIG. 9).

The package 56 shown in FIG. 1( b) is the same as the package 56 a ofthe existing semiconductor module 47 (see FIG. 17( b)), including thedisposition of each of the terminals.

Thus the package 56 used in the semiconductor module 100 of FIG. 1 canbe used in common with the existing package 56 a of the semiconductormodule 47 of the prior art shown in FIG. 17( b), so that there is noneed to develop a new package for the three-level inverter 500, andconsequently the development period for the first semiconductor module100 can be shortened and costs can be reduced.

Further, a first semiconductor module 100 can be provided which easilysupports broad ranges of current ratings and voltage ratings, withoutdeveloping a new package.

Example 2

FIG. 3 is a diagram of the configuration of the semiconductor module ofa second example of the invention, in which FIG. 3( a) is a circuitdiagram of principal components and FIG. 3( b) is a plane view ofprincipal components. FIG. 4 is a diagram of the internal configurationof the semiconductor module of FIG. 3. FIG. 4 shows an example in whichfour second reverse blocking IGBTs 6 having a reverse breakdown voltageare parallel-connected, four second IGBTs 3 not having a reversebreakdown voltage (normally used IGBTs) are parallel-connected, and fourFWDs 4 are disposed antiparallel to each of the normal second IGBTs 3.This disposition is the same as that in FIG. 18 in which the FWD (D1) isremoved. The Q22 terminals a and b are connected within the package 56,with the Q22 terminal a disposed on the package 56, as a terminalcorresponding to E1C2 in FIG. 17.

A feature of this second semiconductor module 200 is that the secondIGBT 3 not having a reverse breakdown voltage and antiparallel-connectedto the FWD 4 of the lower arm of a series-connected circuit of thethree-level inverter, and the second reverse blocking IGBT 6 having areverse breakdown voltage of the AC switch, are accommodated in the samepackage 56 as an existing package 56 a.

In the configuration of FIG. 3, the second semiconductor module 200 isconfigured with the second IGBT 3, with an antiparallel-connected FWD 4,series-connected to the second reverse blocking IGBT 6, and with thecollector of the second IGBT 3 connected to the emitter of the secondreverse blocking IGBT 6.

The low-potential side terminal 8 (E22) connected to the emitter of thesecond IGBT 3, the second intermediate potential auxiliary terminal 12(M22) connected to the collector of the second reverse blocking IGBT 6,the second connection terminal 10 (Q22) connected to the connectionpoint 10 a of the collector of the second IGBT 3 and the emitter of thesecond reverse blocking IGBT 6, and the respective gate terminals G2 andauxiliary emitter terminals E2 of the second IGBT 3 and the secondreverse blocking IGBT 6, are disposed on the package 56 of the secondsemiconductor module 200.

Further, on the package 56 are disposed the gate terminals G3 and G4 andthe auxiliary emitter terminals E3 and E4 respectively of the secondIGBT 3 and the second reverse blocking IGBT 6. Q22 is a terminalcorresponding to E1C2 in FIG. 17.

The second IGBT 3 with the FWD 4 antiparallel-connected is an element ina lower arm of a three-level inverter 500, and the second reverseblocking IGBT 6 is an element in a portion of an AC switch 15 (see FIG.9).

The package 56 shown in FIG. 3( b) is the same as the package 56 a ofthe existing semiconductor module 47 (see FIG. 17) accommodating twoseries-connected IGBT chips of the prior art, including the dispositionof each of the terminals.

Thus the package 56 used in the semiconductor module 200 of FIG. 3( b)can be used in common with the existing package 56 a of thesemiconductor module 47 of the prior art shown in FIG. 17( b), so thatthere is no need to develop a new package for the three-level inverter500, and consequently the development period for the secondsemiconductor module 200 can be shortened and costs can be reduced.

Further, a second semiconductor module 200 can be provided which easilysupports broad ranges of current ratings and voltage ratings, withoutdeveloping a new package.

In the drawings, G3 and E3 are the gate terminal and emitter auxiliaryterminal of the second reverse blocking IGBT 6, and G4 and E4 are thegate terminal and emitter auxiliary terminal of the second IGBT 3.

Example 3

FIG. 5 and FIG. 6 show the upper and lower arm kit of a third example ofthe invention. FIG. 5 is a circuit diagram of principal components, andFIG. 6 is a plane view of principal components.

This upper and lower arm kit 300 is formed of the pair of the firstsemiconductor module 100 to be the upper arm, and the secondsemiconductor module 200 to be the lower arm, of the three-levelinverter 500 shown in FIG. 9 and FIG. 10.

A method for configuring one upper and lower arm of a three-levelinverter 500 using the upper and lower arm kit 300 of FIG. 5 and FIG. 6,in which the upper and lower arms are not connected, is explained.

The first connection terminal 9 (Q11) of the first semiconductor module100 and the second connection terminal 10 (Q22) of the secondsemiconductor module 200 are connected by a first connection conductor13, indicated by a dashed line, and taken to be an output terminal, forexample the U terminal, of the three-level inverter 500 (see FIG. 9 andFIG. 10).

The first intermediate potential auxiliary terminal 11 (M11) of thefirst semiconductor module 100 and the second intermediate potentialauxiliary terminal 12 (M22) of the second semiconductor module 200 areconnected by a second connection conductor 14, indicated by a dashedline, and taken to be an intermediate potential terminal, which is the Mterminal, of the three-level inverter 500.

The high-potential side terminal 7 (C11) of the first semiconductormodule 100 is connected to a P terminal, not shown, of the three-levelinverter 500, and the low-potential side terminal 8 (E22) of the secondsemiconductor module 200 is connected to an N terminal, not shown, ofthe three-level inverter 500.

Thus using the same package 56 as the existing package 56 a, the upperand lower arm kit 300 can be configured, and so the cost of the upperand lower arm kit 300 can be reduced. Further, an upper and lower armkit 300 can be provided which can easily support broad ranges of currentratings and voltage ratings.

Further, the upper and lower arm kit 300 is configured using the firstsemiconductor module 100 and second semiconductor module 200 which arenot connected together.

Example 4

FIG. 7 and FIG. 8 show the upper and lower arm kit of a fourth exampleof the invention, in which FIG. 7 is a circuit diagram of principalcomponents and FIG. 8 is a plane view of principal components.

A difference between the upper and lower arm kit 400 of FIG. 7 and FIG.8 and the upper and lower arm kit 300 of FIG. 5 and FIG. 6 is that Q1and M11 of the first semiconductor module 100 on the upper arm side andQ22 and M22 of the second semiconductor module 200 on the lower arm sideare connected by a third connection conductor 16 and fourth connectionconductor 17, integrating the upper and lower arm semiconductor modules100 and 200.

In this case the upper and lower arms are integrated, so that use isfacilitated. Advantageous effects similar to those of the third exampleare obtained.

Example 5

FIG. 9 and FIG. 10 show the configuration of the three-level inverter ofa fifth example of the invention, in which FIG. 9 is a circuit diagramof principal components and FIG. 10 is a plane view of principalcomponents. In FIG. 10, the first and second DC power supplies 23 and 24of FIG. 9 are not shown.

The terminals Q11 and Q22 of each of the three upper and lower arm kits300 (FIG. 5 and FIG. 6) are connected by first connection conductors 13to serve as the output terminals which are the U terminal, the Vterminal, and the W terminal.

Further, the terminals M11 and M22 of each of the three upper and lowerarm kits 300 are connected by second connection conductors 14, to serveas the intermediate potential terminal which is the M terminal. Thisportion forms the AC switches 15 of the three-level inverter 500 shownin FIG. 9.

The high-potential side terminals 7 (C11) of the first semiconductormodules 100 are connected together by the fifth connection conductor 21to serve as the P terminal of the three-level inverter 500.

Further, the low-potential side terminals 8 (E22) of the secondsemiconductor modules 200 are connected together by the sixth connectionconductor 22 to serve as the N terminal of the three-level inverter 500.

The positive electrode and negative electrode of the first DC powersupply 23 are connected to the P terminal and the M terminalrespectively of the three-level inverter 500, and the positive electrodeand negative electrode of the second DC power supply 24 are connected tothe M terminal and the N terminal respectively of the three-levelinverter 500, to configure the three-level inverter 500. Although notshown, there are also cases in which, by providing intermediatepotential terminals which are M terminals in two places, the wiringinductance connecting the first and second DC power supplies 23 and 24can be reduced.

Thus using three upper and lower arm kits 300, each comprising a firstsemiconductor module 100 configuring the upper-arm side and a secondsemiconductor module 200 configuring the lower-arm side, the three-levelinverter 500 is fabricated, so that the cost of the three-level inverter500 can be reduced. Further, a three-level inverter 500 can befabricated which can easily support broad ranges of current ratings andvoltage ratings.

Example 6

FIG. 11 and FIG. 12 show the configuration of the three-level inverterof a sixth example of the invention, in which FIG. 11 is a circuitdiagram of principal components and FIG. 12 is a plane view of principalcomponents. In FIG. 12, the first and second DC power supplies 23 and 24of FIG. 10 are not shown.

A difference between the three-level inverter 600 and the three-levelinverter 500 of FIG. 9 and FIG. 10 is the use of the upper and lower armkits 400 instead of the upper and lower arm kits 300. In an upper andlower arm kit 400, the first semiconductor module 100 and secondsemiconductor module 200 are connected by third and fourth connectionconductors 16 and 17, and thus a seventh connection conductor 25 andeighth connection conductor 26 are connected to the third and fourthconnection conductors 16 and 17 at the connection points 18 and 19respectively, to serve as the M terminal, U terminal, V terminal, and Wterminal.

The positive electrode and negative electrode of the first DC powersupply 23 are connected to the P terminal and the M terminalrespectively of the three-level inverter 600, and the positive electrodeand negative electrode of the second DC power supply 24 are connected tothe M terminal and the N terminal respectively of the three-levelinverter 600, to configure the three-level inverter 600. Although notshown, there are also cases in which, by providing intermediatepotential terminals which are M terminals in two places, the wiringinductance connecting the first and second DC power supplies 23 and 24can be reduced.

In the case of this three-level inverter 600 also, advantageous effectssimilar to those for the three-level inverter 500 are obtained.

Further, examples were given in the first through sixth examples inwhich IGBTs were used as the semiconductor elements, but power MOSFETsmay also be used. However, in the case of power MOSFETs incorporatingFWDs, there is no need for external FWDs. Further, because power MOSFETsdo not have a reverse breakdown voltage, diodes connected in series mustbe used with the power MOSFETs used in places corresponding to reverseblocking IGBTs.

The above briefly describes the principles of the invention.

Numerous modifications and changes can be made by a person skilled inthe art, and the invention is not limited to the above-described preciseconfigurations and application examples, and all correspondingmodifications and equivalents are to be regarded as included in thescope of the invention as described in the attached claims andequivalents thereof.

EXPLANATION OF REFERENCE NUMERALS

-   1 First IGBT-   2, 4 FWD-   3 Second IGBT-   5 First reverse blocking IGBT-   6 Second reverse blocking IGBT-   7 High-potential side terminal (C11)-   8 Low-potential side terminal (E22)-   9 First connection terminal (Q11)-   9 a, 10 a, 18, 19 Connection point-   10 Second connection terminal (Q22)-   11 First intermediate potential auxiliary terminal (M11)-   12 Second intermediate potential auxiliary terminal (M22)-   13 First connection conductor (output terminal: U terminal, V    terminal, N terminal)-   14 Second connection conductor (intermediate potential terminal: M    terminal)-   15 AC switch-   16 Third connection conductor-   17 Fourth connection conductor-   21 Fifth connection conductor (P terminal)-   22 Sixth connection conductor (N terminal)-   23 First DC power supply-   24 Second DC power supply-   25 Seventh connection conductor (intermediate potential terminal: M    terminal)-   26 Eighth connection conductor (output terminal: U terminal, V    terminal, W terminal)-   56 Package (same as the existing package 56 a)-   100 First semiconductor module-   200 Second semiconductor module-   300, 400 Upper and lower arm kit-   500, 600 Three-level inverter

1. A semiconductor module, comprising: a first asymmetrical switchingelement having a first reverse breakdown voltage, andantiparallel-connected to a freewheeling diode; a first reverse blockingswitching element having a second reverse breakdown voltage that isgreater in magnitude than the first reverse breakdown voltage of thefirst asymmetrical switching element, and series-connected to the firstswitching element; a first package, in which the first asymmetricalswitching element and the first reverse blocking switching element areaccommodated; a high-potential side terminal (C11), disposed on an upperface of the first package and connected to a high-potential side of thefirst asymmetrical switching element; a first intermediate potentialauxiliary terminal (M11), disposed on the upper face of the firstpackage and connected to a low-potential side of the first reverseblocking switching element; and a first connection terminal (Q11),disposed on the upper face of the first package and connected to thefirst asymmetrical switching element and to the first reverse blockingswitching element.
 2. A semiconductor module, comprising: a secondreverse blocking switching element having a second reverse breakdownvoltage; a second asymmetrical switching element having a reversebreakdown voltage that is lower in magnitude than the second reversebreakdown voltage of the second reverse blocking switching element,series-connected to the second reverse blocking switching element andantiparallel-connected to a freewheeling diode; a second package, inwhich the second reverse blocking switching element and the secondasymmetrical switching element are accommodated; a second intermediatepotential auxiliary terminal (M22), disposed on an upper face of thesecond package and connected to a high-potential side of the secondreverse blocking switching element; a low-potential side terminal (E22),disposed on the upper face of the second package and connected to alow-potential side of the second asymmetrical switching element; and asecond connection terminal (Q22), disposed on the upper face of thesecond package, and connected to the second reverse blocking switchingelement and to the second asymmetrical switching element.
 3. Thesemiconductor module according to claim 1, wherein the firstasymmetrical switching element is an insulated-gate bipolar transistor,and the first reverse blocking switching element is also aninsulated-gate bipolar transistor, the collector of which is thehigh-potential side and the emitter of which is the low-potential side.4. The semiconductor module according to claim 2, wherein the secondasymmetrical switching element is an insulated-gate bipolar transistor,and the second reverse blocking switching element is also aninsulated-gate bipolar transistor, the collector of which is thehigh-potential side, and the emitter of which is the low-potential side.5. An upper and lower arm kit, comprising of a first semiconductormodule for an upper arm and a second semiconductor module for a lowerarm in a three-level inverter, wherein the first semiconductor moduleincludes: a first asymmetrical switching element having a first reversebreakdown voltage, and antiparallel-connected to a freewheeling diode; afirst reverse blocking switching element having a second reversebreakdown voltage that is greater in magnitude than the first reversebreakdown voltage of the first asymmetrical switching element, andseries-connected to the first switching element; a first package, inwhich the first asymmetrical switching element and the first reverseblocking switching element are accommodated; a high-potential sideterminal (C11), disposed on an upper face of the first package andconnected to a high-potential side of the first asymmetrical switchingelement; a first intermediate potential auxiliary terminal (M11),disposed on the upper face of the first package and connected to alow-potential side of the first reverse blocking switching element; anda first connection terminal (Q11), disposed on the upper face of thefirst package and connected to the first asymmetrical switching elementand to the first reverse blocking switching element, and wherein thesecond semiconductor module includes: a second reverse blockingswitching element having a second reverse breakdown voltage; a secondasymmetrical switching element having a reverse breakdown voltage thatis smaller in magnitude than the second reverse breakdown voltage of thesecond reverse blocking switching element, series-connected to thesecond reverse blocking switching element and antiparallel-connected toa freewheeling diode; a second package, in which the second reverseblocking switching element and the second asymmetrical switching elementare accommodated; a second intermediate potential auxiliary terminal(M22), disposed on an upper face of the second package and connected toa high-potential side of the second reverse blocking switching element;a low-potential side terminal (E22), disposed on the upper face of thesecond package and connected to a low-potential side of the secondasymmetrical switching element; and a second connection terminal (Q22),disposed on the upper face of the second package, and connected to thesecond reverse blocking switching element and to the second asymmetricalswitching element.
 6. An upper and lower arm kit, comprising a firstsemiconductor module and a second semiconductor module, wherein thefirst semiconductor module includes: a first asymmetrical switchingelement having a first reverse breakdown voltage, andantiparallel-connected to a freewheeling diode; a first reverse blockingswitching element having a second reverse breakdown voltage that isgreater in magnitude than the first reverse breakdown voltage of thefirst asymmetrical switching element, and series-connected to the firstswitching element; a first package, in which the first asymmetricalswitching element and the first reverse blocking switching element areaccommodated; a high-potential side terminal (C11), disposed on an upperface of the first package and connected to a high-potential side of thefirst asymmetrical switching element; a first intermediate potentialauxiliary terminal (M11), disposed on the upper face of the firstpackage and connected to a low-potential side of the first reverseblocking switching element; and a first connection terminal (Q11),disposed on the upper face of the first package and connected to thefirst asymmetrical switching element and to the first reverse blockingswitching element, and wherein the second semiconductor module includes:a second reverse blocking switching element having a second reversebreakdown voltage; a second asymmetrical switching element having asecond reverse breakdown voltage that is smaller in magnitude than thesecond reverse breakdown voltage of the second reverse blockingswitching element, series-connected to the second reverse blockingswitching element and antiparallel-connected to a freewheeling diode; asecond package, in which the second reverse blocking switching elementand the second asymmetrical switching element are accommodated; a secondintermediate potential auxiliary terminal (M22), disposed on an upperface of the second package and connected to a high-potential side of thesecond reverse blocking switching element; a low-potential side terminal(E22), disposed on the upper face of the second package and connected toa low-potential side of the second asymmetrical switching element; and asecond connection terminal (Q22), disposed on the upper face of thesecond package, and connected to the second reverse blocking switchingelement and to the second asymmetrical switching element, and whereinthe first connection terminal (Q11 terminal) and second connectionterminal (Q22 terminal) are connected by a first connection conductor,and the intermediate potential auxiliary terminal (M11 terminal) of thefirst semiconductor module and the intermediate potential auxiliaryterminal (M22 terminal) of the second semiconductor module are connectedby a second connection conductor.
 7. A three-level inverter, whereinthree of the upper and lower arm kits as in claim 5 are disposed inparallel, and wherein the high-potential side terminals (C11 terminals)of the first semiconductor modules are connected together by a thirdconnection conductor, the low-potential side terminals (E22 terminals)of the second semiconductor modules are connected together by a fourthconnection conductor, the intermediate potential auxiliary terminal(M11) of each of the first semiconductor modules and the intermediatepotential auxiliary terminal (M22) of each of the second semiconductormodules are connected together by a fifth connection conductor, thethird connection conductor and the fifth connection conductor arerespectively connected to a positive terminal and a negative terminal ofa first DC power supply, the fifth connection conductor and the fourthconnection conductor are respectively connected to a positive terminaland a negative terminal of a second DC power supply, the firstconnection terminal (Q11) of each of the first semiconductor modules andthe second connection terminal (Q22) of each of the second semiconductormodules are connected together by a sixth connection conductor, and thethree sixth connection conductors are taken to be output terminals,which are a U terminal, a V terminal, and a W terminal.
 8. A three-levelinverter, wherein three of the upper and lower arm kits as in claim 6are disposed in parallel, and wherein output terminals of thethree-level inverter, which are a U terminal, a V terminal, and a Wterminal, are connected to the three first connection conductors,respectively, the second connection conductors are connected together asan intermediate potential terminal (M terminal), the high-potential sideterminals of the first semiconductor modules are connected together andto a positive terminal of a first DC power supply via a third connectionconductor (P terminal), a negative terminal of the first DC power supplyis connected to the intermediate potential terminal (M terminal), thelow-potential side terminals of the second semiconductor modules areconnected together and to a negative terminal of a second DC powersupply via a fourth connection conductor (N terminal), and a positiveterminal of the second DC power supply is connected to the intermediatepotential terminal (M terminal).